Thermoformable Rear Projection Screen Ink Cracking Prevention
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Solution Overview
Problem
The labor-intensive process of tinting and printing on three-dimensional rear projection screens for animatronic figures results in uneven ink distribution and cracked layers, making it difficult to achieve realistic and uniform coloration, especially for complex shapes like human faces, which are crucial for realistic projections.
Innovation Solution
A method involving the lamination of a flexible thermoformable film with a rear projection screen film, followed by digital printing of radiation-curable inks on both surfaces, and subsequent thermoforming to create a three-dimensional article that can display rear-projected images without cracking or unevenness, using standard printers and UV irradiation for curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If standard printers are used to print on flat rear projection screen material before thermoforming, then printing complexity is reduced and standard equipment can be employed, but the ink layer cracks and distributes unevenly during the thermoforming process
Solution Approach 1:
The patent applies preliminary action by printing and curing the ink layer on the flat screen material before thermoforming. The ink is applied and UV-cured in advance while the material is still planar, ensuring proper adhesion and distribution before the material is stretched into its three-dimensional form.
Solution Approach 2:
The patent utilizes parameter changes by employing radiation-curable inks that transition from liquid to solid state through UV irradiation. This phase change allows the ink to be applied in liquid form for easy printing, then cured to a flexible solid state that can withstand thermoforming without cracking.
2Manufacturing precision
If labor-intensive manual tinting is performed on completed three-dimensional articles, then nuanced skin tones and realistic coloration can be achieved, but production time and labor costs increase significantly
Solution Approach 1:
The patent applies preliminary action by performing the tinting and skin tone application on the flat screen material before thermoforming. This allows standard printing equipment to be used instead of manual airbrushing, dramatically increasing production efficiency while maintaining color realism.
Solution Approach 2:
The patent replaces the manual mechanical tinting process (airbrushing) with an automated printing system. Radiation-curable inks are applied through printing technology, substituting skilled manual labor with automated equipment that achieves consistent, realistic coloration at high speed.
3Shape
If the screen material is formed into complicated three-dimensional shapes, then realistic animatronic figures can be created, but maintaining uniform thickness and light diffusion properties becomes difficult
Solution Approach 1:
The patent uses flexible thermoplastic screen materials that can be thermoformed into complex three-dimensional shapes. The flexibility of the thin film allows it to conform to complicated geometries while maintaining uniform thickness, enabling realistic animatronic figures with proper light diffusion properties.
Solution Approach 2:
The patent utilizes phase transitions of thermoplastic materials during thermoforming. The material is heated to a pliable state, formed into the desired three-dimensional shape, then cooled to set the form. This phase change process allows complex shaping while maintaining uniform thickness and optical properties.
4Reliability
If radiation curable inks are used and UV irradiation is applied, then the ink layer cures uniformly and maintains flexibility during thermoforming, but additional equipment for UV curing is required
Solution Approach 1:
The patent employs radiation-curable inks that change from liquid to solid state through UV irradiation. This parameter change (phase transition) allows the ink to be applied easily in liquid form, then rapidly cured to a flexible solid that can withstand thermoforming without cracking or losing adhesion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the creation of high-quality, uniformly colored three-dimensional articles that can stretch significantly without visual degradation, enabling realistic and efficient production of animatronic figures with nuanced skin tones and shading, reducing material waste and labor costs.
Implementation Method 1
the adhesive layer contacts the rear projection screen film at the nip to form the laminate
Implementation Method 2
the inks are radiation curable inks, and the method further includes irradiating the inks after printing. In some embodiments, the irradiating is UV irradiating.
Data Source
AI summary
Disclosed herein are materials and methods used to form a three dimensional (3D) article having a printed layer thereon. The 3D articles are capable of displaying rear projected images, effectively as a 3D “screen” for displaying an image or a movie. The 3D articles are used as standalone articles or as a portion of an animatronic figure. The articles are made by forming a substantially planar thermoformable laminate including a rear projection screen material, printing and curing a radiation curable ink onto one or both sides of the laminate, and thermoforming to impart a shape to the laminate.